Air-cooled heat exchangers

Cutting-edge technologies for individual solutions

engineering for a better world

GEA Heat Exchangers

Benefiting from the HX factor: Focussed

competence and excellence in heat exchanging
Efficiency and sustainability are standards. GEA Heat Exchangers
(HX stands for heat exchange) offers you more. Because we have
the HX factor. Everyone at GEA has it. Every team. Every employee.
It can be found in all our products and services. It makes the
difference. And gives you the edge in heat exchanging. Thanks to
engineering know-how based on market experience and expertise.
With skills and understanding leading to the right solution even
in the most complex projects. With reliability in every situation.
With enjoyment of the challenge. With commitment, foresight and
precision. This is all a part of our HX Factor. Experience it. Benefit
from it.

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Your requirements define our solutions

Wherever cooling processes are required within your industrial production facilities, we regulate it
all to a precise temperature. Oil, gas and chemicals, steelworks and power stations, from paper to
textiles GEA provides you with individual solutions throughout the world:
Air-cooled heat exchangers and condensers
Heat exchangers with galvanized finned tubes
Our company was founded in 1920. In the meantime, we are active in engineering and manufacturing
around the globe as part of the GEA Group and integrated in an international network of up-to-date
production locations.
Our portfolio includes all air cooler designs for all applications, starting with simple components
and ending with complex process engineering. Your benefits include: manufacturing quality,
economic efficiency and flexibility a winning combination in terms of efficiency.

The best solutions for your needs are ours.

When it comes to air cooling, we have more than one string to our bow for you. Feel free to have
high expectations of us we are on the same level.
Our range comprises the most varied finned tube types and every conceivable header design in all
materials or material combinations as well as complete service packages. Our delivery includes the
benefits of a technology leader with a complete range of services:

reliable: preliminary and feasibility studies innovative: own research and development
precise: measuring of vibrations, thermal and acoustic power
selected: material and manufacturing quality
experienced: familiar with industrial requirements
productive: application-related solutions
profitable: energy-efficient air cooling
complex: from engineering to commissioning
You can have it all or make your choice. So you are flexible. You get the
solution you want because we speak your language. This boosts your
competitiveness. We are never far from wher you are. Saving you time
in the long run.

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One feature of our quality:

Your satisfaction
GEA air coolers often have to prove their worth under extreme conditions and guarantee reliable
operation. This is why a team of experts including engineers, welding experts and other quality
inspectors scrutinizes every apparatus and every single component very precisely. This procedure
ensures that we meet all quality requirements. And we achieve this in complete control as numerous
certifications demonstrate.These certifications comprise both the safety requirements according to
international pressure vessel regulations PED 97/23/EG, EN13445, ASME (U-Stamp) and special
certificates for the Chinese (SQL) and the Russian (GOST) market. As we also install and commission
our plants if you want us to, our installation department is comprehensively trained in all aspects
of occupational safety. Our confirmation: the SCC Certificate (Safety Certificate Contractors).

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GEA air-cooled heat exchangers

always in the right place
Wherever cooling is required in production processes we offer
you the optimum air cooler for your application:
Refineries
Petrochemistry
Steelworks, steel industry
Gas facilities
Power stations
Other industrial cooling applications

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Inspired by the efficiency concept.

Designed for maximum performance.

Finned tube bundle

Fan

Fan ring

Heating coils

Air plenum

Louvers

Pulley
Drive belt
Supporting structure

Motor

Air cooler bank

The air cooler bank essentially consists of finned tube bundles, fan rings, axial fans with suitable drive units and a supporting structure. It can be
equipped individually with maintenance platforms, louvers and other equipment as requested by the customer.

GEA constantly underpins its technological leadership with new product developments. This
includes special high-performance finned tubes with optimized material and design, enabling
clearly more efficient heat exchange. This pays off for you in two ways. The investment cost
is reduced and you save in operating costs. Both benefits can be achieved while enjoying highlevel product reliability even under extreme conditions.
In addition, GEA offers you a choice you rarely find elsewhere the choice between aluminium
fins and steel fins on the finned tube systems. Both variants have specific benefits.
Finned tube bundles with aluminium fins are considerably more lighter, are insensitive to
soiling and easy to clean. On the other hand, systems using galvanized steel offer a very long
service life of up to 30 years, are extremely resistant to mechanical influences such as hailstorms
and provide optimum corrosion protection as aluminium.

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Depending on your specific requirement: GEA air coolers are oriented towards the respective process requirements and
the particular features of the location. Regardless of design characteristics, unhindered air feeding and discharge must
be ensured. Where space is at a premium, roof structures are used.

Header
(outlet)
Vent/
drain

Tube sheet
(fixed side)

Bracket

Cover

Header
(inlet)

Gasket

Guide bolt
Cover plate
Side wall
Lug

Tube sheet
(floating side)

Finned tubes

Finned tube bundle

A finned tube bundle consists of finned tubes (in special cases unfinned tubes are also possible), the headers
for distributing the product and a supporting frame.

Air coolers are used in fundamentally different and sometimes extremely difficult ambient conditions.
This refers to both production processes and climate-related conditions. What is needed are designs
that are up to these requirements at any time, while also taking the customers wishes into account.
From the very beginning, our experts have designed and realised the most varied units for all
branches of industry. Multi-faceted experience combined with an eye for everything that is feasible
produce solutions which integrate perfectly into your industrial production.

Where special solutions are called for

GEA develops suitable special designs for the specific applications of our customers. Circulation air
coolers, acid coolers with anode protection system, high-pressure coolers with baffles or welded lip
seals up to wind tunnel coolers we manufacture what you need. And how you need it, e.g. as a
roof-mounted unit with forced draft or as an in-line unit with induced draft. To achieve successful
solutions, we also use the golden mean with the GEA evaporation air cooler which combines the
benefits of a dry air cooler with those of a wet cooler.

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Finned tubes in detail

Groovy Fin tube type

Extruded tube type

L Fin tube type

Product benefits:

Product benefits:

Product benefits:

new patented high-performance finned

compared with similar fins, extruded

large contact area between tube and fins

tube, pioneering technology

resists high loads, both thermally and
mechanically
extremely dimensionally stable
hardly any maintenance is required

maximum reliability

optimised surface, less fans clearly

reduced energy consumption
less space required, less cabling less
installation effort

fins consist of more than 40% more

developed for low temperatures

well protected against atmospheric

necessitating a certain corrosion

corrosion

protection of the tube wall

very sturdy design resists mechanical

damage very well

Design:

easy to clean with steam or water

The fin base is pre-shaped to form a L and

different core tube materials for different

wrapped around the core tube while

requirements can be used with almost

applying tensile stress. Every fin has

all chemically aggressive media

contact with an adjoining fin. This protects

the core tube when handling less aggressive

economically very profitable saves

labour, material and costs

enable good heat transfer

aluminium, thus the core tube is very

Design:

media. In addition, the manufacturing

The fins are rolled from a hollow blank tube

process enables the use of relatively thin-

Design:

slid over the core tube. In this process, the

walled core tubes.

The fin strip is subject to tensile stress and

inner diameter of the hollow blank tube is

inserted into a pre-shaped spiral core tube

reduced and at the same time, the tube is

groove and firmly rolled into the groove in

pressed on the core tube.

Fin material: aluminium

Core tube material: All metal materials can

a rolling process using high pressure. The

displaced material is then pressed on the fin

Result: a mechanically solid joint with

side.

good heat transfer properties

Fin material: aluminium

Fin material: aluminium

Core tube material: all materials which can

Core tube material: all metal materials

be used.
Maximum operating temperature: 130C

be easily machined.
Maximum operating temperature: 300C
Maximum operating temperature: 400C

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The economic profitability of an air-cooled heat exchanger depends on the capacity of the finned tubes. The capacity results
from the transfer of the maximum heat exchanged in the smallest possible space while keeping thermodynamic losses
on the air side low.

FE/KE/AE tube types

XE tube type

PI/HI tube type

Product benefits:

Product benefits:

Product benefits:

the elliptic shape enables excellent

special design for high pressure ratings

thermodynamic properties and air-side

thermodynamic properties
less vortex formation results in reduced
pressure loss on the air side
additional baffle surfaces/turbulators
achieve very good heat transfer
coefficients
rectangular fins ensure that the face
area remains small and that the design
volume is used optimally

and restricted space

the excellent properties of galvanized

larger clearance between the elliptic

the geometry of round tubes, resulting

core tubes for applications with

in high rigidity

increased soiling hazard provides

reduced size due to design featuring two

tubes in one fin
easy to clean with high-pressure water

is preferably used for combustion air

heaters and air coolers
Design:

Manufacturing: similar to FE tube

The steel strip is wrapped around the core

tube as a spiral. Subsequent hot-dip

Fin material: Steel

galvanizing ensures heat transfer and

corrosion protection.

optimum corrosion protection

easy to clean with high-pressure water

good cleaning possibilities

without damaging the fins.

to thermal and mechanical loads

galvanization in a dipping bath provides

type

tubes with steel fins are combined with

wide galvanized fin collar for excellent

heat transfer and absolute insensitivity

pressure losses are similar to the FE tube

Core tube material: Steel/stainless steel

Fin material: Steel

Design:
The fins are punched first and then

Maximum operating temperature: 360 C

Core tube material: Steel/stainless steel

automatically installed on the tube,

followed by complete galvanization in a

Maximum operating temperature: 360 C

dipping bath.
Fin material: Steel
Core tube material: Steel / stainless steel
Maximum operating temperature: 360 C

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Headers in detail

Cover plate header with

through bolts

Cover plate header with

stud bolts

Welded header (D type)

This header version has a removable cover

In this version, the nozzles are arranged at

The inexpensive header design is mainly

to enable easy inspection and cleaning of

the top and at the bottom. The benefit: you

used for clean products or a high vacuum.

the inner tube walls. For inspections it is

can remove the cover plate without

The tubes are welded into tube sheets, and

generally sufficient to remove only a

dismantling any tubes. The cover plates are

D type headers with the required

manifold because this already offers a

also available with built-in nozzles.

connecting nozzles are welded on.

partial view of the tubes through the

nozzles.

Depending on temperature and gasket

type, this header works up to an operating
pressure of 40 bar. GEA can manufacture
special versions for all applications beyond
this range.
Both cover plate versions have either
welded-in or rolled-in tubes.

Depending on the header version, the tubes are either welded or rolled into the tube sheets.
Different header designs are available for the different applications and requirements.

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The specific feature: GEA headers are available in all material types. They can be used in all pressure and
temperature ranges and therefore predestined for various media and marginal conditions.

Plug-type header

High-pressure header with return

segments

High-pressure header with

welded return bends

Here the tubes are usually rolled into the

A threaded plug with a soft iron seal is

This high-pressure header, just as the variant

plug headers; in special cases, they are

provided opposite every tube. This plug can

with the return segments, is perfectly suited

directly welded into the tube sheets.

be simply removed for re-rolling or for

for high temperature differences as the

internal cleaning of the tubes.

finned tubes expand individually.

A threaded plug with a soft iron seal is

provided opposite every tube; this seal can
be easily removed for re-rolling or internal
cleaning of the tubes. As the nozzles are
fitted at the top or bottom of the header,
dismounting the tube connections is not
required for inspections and cleaning.
The header design can be used even at high
pressure levels.

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Fan drive details

Direct drive

Belt drive for forced draft configuration

The fan is fitted directly to the motor shaft, using a flange. Fan

This version uses pulleys for reducing the motor speed to the required

speed and motor speed are identical.

fan speed.

Belt drive for induced draft configuration

Gearbox drive

When waste air temperatures are low, the motor can also be

This drive includes a fan joined directly to the output shaft of the

installed above the bundle.

gearbox motor.

Different versions, one common feature: GEA air cooler fan drives are convincing with their high degree of reliability
and their low vibration level. They are available in various diameters and offer infinitely variable speed control, depending on the version.

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Configurations
Vertical configuration

Horizontal configuration

Forced draft

Induced draft

Forced draft

Roof-mounted configuration

Induced draft

In-line configuration

Forced draft

Induced draft

GEA offers numerous different air cooler versions in order to meet differing requirements of the process and the place of installation. Regardless of the selected design, free air feeding and discharge must be ensured. Where space is at a premium,
roof-mounted configurations are frequently used.

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We are adapting to low-noise

Our inventive genius is inspired in particular in two ways. One way is to create efficient industrial solutions with
customized products which pay off for our customers in every respect. The other way is to play a leading role also
in environmental matters, using advanced technologies. There is a lot at stake here to make less noise. Because,
apart from examples where a roaring engine is a matter of good taste, the trend with automobiles indicates that
the general direction is towards noise reduction.
Apart from the dB(A) measuring unit indicating sound pressure level, factors such as the duration of the noise,
time of day or frequency also serve for classifying and evaluating so-called acoustical events such as traffic. From
40 dB(A) and above, sound sources can affect communication, from 65 dB(A) health risks start appearing, from
85 dB(A) there is an unpleasant pressure on the ears, and from 120 dB(A) noise becomes unbearable.
The example of a passenger car: At a distance of 10 metres, the sound pressure level is between 60 and just under
80 dB(A). This value is equal to the former industrial standard at a distance of 1 metre. When converting this to
100 metres, this value is 55 dB(A) which is roughly equal to moderate volume.

The good news: We can make even less noise. Which is of particular benefit in steel plants, refineries or natural
gas compressor stations in the framework of network extensions where GEA air coolers are used.

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A technological leader such as GEA has only one goal stay at the top. So we are not revealing any secrets when
we talk about considerable investments in research and development. A part of this has been used for soundproofing
which, of course, you will hardly hear.
If your industrial location is quite close to residential buildings or near a town, you know the permitted threshold
values in decibels. These conditions require soundproofing measures for machinery and plants. When requirements
are strict today and a medium-size plant is involved, the standard is only 57 dB(A) at a distance of 1 metre, equalling
35 dB(A) at 100 metres. Anyone living in such surroundings may count himself absolutely lucky.
GEA offers you solutions with the necessary noise levels, all of which comply with existing threshold values. The
special soundproofing of the electric motors in frequency converter mode is ensured by an encapsulation which
also supplies the electric motor with a sufficient amount of cooling air.
This low-noise drive has even more benefits to offer. Low speeds and a lower air throughput reduce energy
consumption, which improves profitability. Moreover, this opens up another source for cost reductions the health
of your employees. And you cant put a price on that.

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Your investments are in good hands

GEA is the specialist for air-cooled heat exchangers and plays a

GEA employees are continuously trained in safety, health and

leading role in industrial applications, innovative development

environmental issues and are recurringly examined by an

and worldwide use of this technology. GEA stands out as a partner

independent institution. The certificate has a duration of 3 years

for design, execution, planning and service of customized solutions.

after which the examination is repeated.

The GEA air coolers service applies this knowledge and these skills
in a goal-oriented and powerful department.

The strong points of a market leader are implemented in competent

and quick service. The range of services is detailed below:

A team of highly qualified fitters and technicians ensures optimum

plant performance, preventing damage and plant standstill and

Regular plant inspections

supporting our customers with additional expertise and labour.

Preventive maintenance

The GEA air coolers service is the partner to contact for

Performance checks and improvement of existing plants

comprehensive services tailored to your needs.

Adaptations for reasons such as meeting noise reduction

requirements, increasing capacity or complying with stricter

Safety as well as responsible handling of health and environmental

protection standards during installation and servicing have always
played an important role in our company. The GEA air coolers

environmental requirements
Replacement and overhaul: modification of cooling components,
depending on the customers wishes

installation and service department has been awarded a SCC

Procurement of spare parts and special tools

Certificate in May 2002. This certificate issued by TUEV Cert

Support of plant operators in planning and implementation of

Certification Agency for Management-Systems of the RW TUEV

documents that safety is a declared company objective and that

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standstills

 Independent execution of work during standstill

periods, from planning through to commissioning
of air coolers
Consulting in case of problems with air coolers
Elaboration of customer-oriented special solutions
for maintenance and conversions of existing air
coolers with the goal of avoiding or minimizing
production downtimes
Complete installation of air coolers and their
components

from

planning

through

to

Automated outside cooler cleaning.

Installation of air coolers,

Vattenfall, Berlin.

commissioning.
Provision of control personnel for service and
installation.

The genuine spare parts and special tools we use

enable smooth plant operation, even after many
on-stream hours. GEA Luftkhler GmbH spare parts
service delivers all spare parts and tools required for
air cooler systems as quickly as possible.

Air cooler with an automatically

Maintenance work on fans.

travelling cleaning platform

No matter if you use the service on a regular basis or

occasionally, as a supplement or a substitute for your
own technical service, for GEA plants or plants of other
manufacturers: The GEA air cooler service for dry
coolers offers tailor-made service agreements to suit
your needs.
Air cooler maintenance platform.

Various spare parts.

Repair welds on a leaky tube

bundle.

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Your partners for air-cooled heat exchangers throughout the world

We are there, whenever and wherever you need us

Europe

GEA Batignolles Technologies

Thermiques S.A.S.

25, rue du Ranzai,

44300 Nantes, France

Telefon: +33 (0) 240 68 2424
btt@gea.com

Africa

GEA Aircooled Systems (Pty) Ltd.

Fax Aberdein Street, Roodekop,

Germiston 1401, South Africa

Telefon: +27 (0) 11 861 1500
gas@gea.com

Asia

GEA Heat Exchangers S.r.l.

Via Galileo Ferraris, 3

21020 Monvalle (VA), Italy

Telefon: +39 0332 799 534
gsc.info@gea.com

GEA Ibrica, S.A.

Barrio de San Juan 28,

48140 Igorre Vizcaya, Spain

Telefon: +34 - 94 631 50 00
geaiberica.igorre@gea.com

GEA Mashimpeks

Malaya Pochtovaya str., 12

Moscow, 105082, Russia

Telefon: +7 (495) 234-95-03 (ext. 202)
info.mashimpeks@gea.com

GEA Technika Cieplna Sp. z.o.o,

Oswiecimska Str. 100 B,

45-641 Opole, Poland

Telefon: +48 77 402 00 50
sekretariat.gea-tc@gea.com

GEA Batignolles Thermal

Technologies (Changshu) Co., Ltd.
Factory

66, Xin An Jiang Road, Changshu

Southeast Development Zone,

Changshu 215504, Jiangsu Province,

P.R. China

Telefon: + 86 0512 5230-6120

Shanghai Office

Floor 27, Junyao International Plaza,

789, Zhao Jia Bang Road

Shanghai 200032, P.R. China

Telefon: + 86 021 6196-0700
bttc@gea.com

GEA Batignolles Thermal

Technologies L.L.C.
Road L New Salwa Industrial Zone,
PO Box 23794 Doha, Qatar
Telefon: +974 411 49 84

North America

GEA Luftkhler GmbH

Dorstener Str. 484,

44809 Bochum, Germany

Telefon: +49 234 980-1961
info-glk@gea.com

www.gea.com

GEA do Brasil Intercambiadores Ltda.

Estrada SP 354, Serra dos Cristais,

Franco da Rocha / SP, Brazil

Telefon: +55 11 4447-8800
vendas.gdb@gea.com

GEA Heat Exchangers, Inc.

Rainey Division

5202 West Channel Road,

Catoosa, Oklahoma, USA 74015,

Telefon: +1 (918) 266-3060
aircoolers.rainey@gea.com

GEA Canada, Inc.

Rainey Division

Lethbridge, AB T1H 5V9,
Canada

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South America

Sales/Service

Production/Manufacturing

GEA air coolers complete solutions all over the world

GEA Heat Exchangers combines different areas of service into one single complete solution from a single source, enabling more effective control of complex heat exchange processes. This procedure also accelerates order execution and simplifies both preventive
and regular plant maintenance. In this way, GEA generates a clear and personally addressable responsibility for the entire project
implementation process. Our highly skilled employees make all important processes in industrial manufacture and air conditioning
engineering available in a tight worldwide network. GEA has set new standards for efficiency, reliability and availability of heat exchanging equipment. With its production and service locations throughout the world, GEA Heat Exchangers offers a unique industrial network providing outstanding engineering and technical competence in regional services as well as comprehensive support
for our customers in a wide range of special applications.

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 GEA Group AG. All rights reserved. 06/12 . kpad

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